System and method for processing stacks of articles

ABSTRACT

A stack of articles having a stack guide disposed thereon is disclosed. The stack guide comprises identifiers which relate to information about the stack and the articles within the stack, and to the orientation of the stack. The stack guide also comprises a guide for binding straps which can be identified during an unloading process.

BACKGROUND OF THE INVENTION

1. Field

This disclosure relates to identifying features of a stack of articles to facilitate handling of the articles in the stack.

2. Description of the Related Technology

Articles are frequently bound into stacks of articles. The stacks need to be unbound and loaded into trays in order to accomplish further processing. The articles in a single stack may share characteristics, such as special treatment conditions, but the characteristics may vary from stack to stack. The variation in stack characteristics requires separate and individualized handling for each stack. Furthermore, the articles within one stack may not have a uniform thickness between all the articles. For example, where the articles are bound articles, the bound edge of the article may be thicker than the unbound edge of the article. When stacking more than one stack, it may be desirable to offset the binding edges to compensate for the thickness of the binding.

Current methods for unbinding stacks require manual identification of the stack, its characteristics, the orientation of the bindings, and manual removal of the binding material, or straps. The present application provides a smart stack having a stack guide which provides for automated handling of multiple stacks and allows greater speed and ease when handling stacks of articles.

SUMMARY

In one aspect of the present development, a stack guide comprises a first surface configured to be supported in a fixed location with respect to an article in a stack of articles; a second surface which comprises: a securing guide configured to receive one or more securing members for bundling the stack of articles; and at least one information source, the information source including a stack identifier and a stack orientation indicator.

In some embodiments, the stack guide comprises a supplemental identifier.

In some embodiments, the stack identifier is a one or two-dimensional barcode.

In some embodiments, the stack orientation indicator is a marking recognizable by a computerized visual recognition system.

In some embodiments, the supplemental identifier comprises an RFID tag.

In some embodiments, the articles are articles of mail.

In some embodiments, the securing guide forms a depression in the second surface, and wherein the stack identifier and the stack orientation indicator are disposed on opposite sides of the strap channel.

In another aspect, a system for bundling articles into a stack comprises a plurality of articles arranged into a stack, having the bound edge of each of the plurality of articles aligned within the stack; a first surface configured to be supported in a fixed location with respect to an article in a stack of articles; a second surface which comprises: a securing guide configured to receive one or more securing members for bundling the stack of articles; and at least one information source, the information source including a stack identifier and a stack orientation indicator a securing guide configured to receive one or more straps for bundling the stack of articles; and wherein the stack identifier and the stack orientation indicator are disposed on opposite sides of the securing guide; and one or more straps surrounding the stack of articles and passing through the securing guide, wherein a gap is created between the strap and a topmost article in the stack proximate to the stack guide.

In some embodiments, the system further comprises an automatic unloading machine, wherein the automatic unloading machine is configured to read the stack identifier and the stack orientation indicator.

In some embodiments, the gap between the strap and the topmost article in the stack is sized to accept a strap cutting tool on the automatic unloading machine.

In some embodiments, the stack guide further comprises a supplemental identifier.

In some embodiments, the stack identifier is a one or two-dimensional barcode.

In some embodiments, the stack orientation indicator is a marking recognizable by a computerized visual recognition system.

In some embodiments, the supplemental identifier comprises an RFID tag.

In some embodiments, the stack of articles comprises articles of mail.

In some embodiments, the securing guide forms a depression in the second surface.

In another aspect, a method of processing a stack of articles comprises receiving, into an automatic unloading apparatus, a stack of articles which are bound with a binding material and which includes a stack guide; reading a stack identifier disposed on the stack guide; retrieving stack information corresponding to the stack identifier from a database; identifying the orientation of the stack using an orientation identifier disposed on the stack guide; rotating the stack in response to the identified orientation; identifying the location of the straps; cutting the straps; and unloading the articles from the stack in response to the retrieved stack information.

In some embodiments, the system further comprises placing the articles from the stack into a tray with a bound edge of each of the articles aligned.

In some embodiments, the stack guide further comprises a supplemental identifier.

In some embodiments, the system further comprises reading the supplemental identifier.

In some embodiments, the stack of articles comprises articles of mail.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a stack of articles having a stack guide.

FIG. 2 is a top plan view of a stack guide on a stack of articles.

FIG. 3 is a block diagram depicting an automatic unloading apparatus.

FIG. 4 is a perspective view of an embodiment of an automatic unloading apparatus.

FIG. 5 is a flow chart illustrating a method of using a stack guide in the process of unpacking a stack of articles.

DETAILED DESCRIPTION

In the following detailed description, reference is made to the accompanying drawings, which form a part thereof. In the drawings, similar symbols typically identify similar components, unless context dictates otherwise. Thus, in some embodiments, part numbers may be used for similar components in multiple figures, or part numbers may vary depending from figure to figure. The illustrative embodiments described in the detailed description, drawings, and claims are not meant to be limiting. Other embodiments may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented here. It will be readily understood that the aspects of the present disclosure, as generally described herein, and illustrated in the Figures, can be arranged, substituted, combined, and designed in a wide variety of different configurations, all of which are explicitly contemplated and made part of this disclosure.

The present disclosure relates to a stack guide used in a stack of articles to improve ease and efficiency of handling stacks of articles. Specifically, the present disclosure relates to processing articles when unbundling stacks of articles and placing the articles into equipment for further processing, such as into a tray or other sorting apparatus for sorting. In some embodiments, the stack guide may be used when handling stacks of mail pieces. In some embodiments, the stack guide may be advantageously used when handling flats. Flats may be articles, such as those comprising magazines and catalogs, which are too long in one direction to be considered standard sized letters. Flats are often bound on one edge, and unbound on another edge. Some methods of stacking articles alternating bound and unbound edges within a single stack of articles. In some embodiments, for example, when used with a stack guide in a smart stack, the articles within a stack may stacked having the bound edges aligned. This may create a stack which is thicker on the bound edge and thinner on the unbound edge, and may not be suitable for stacking on another stack of articles. Stacks of articles, such as stacks of magazines, may be stacked on top of each other in an alternating fashion. For example, the bound edges of articles in one stack may be aligned with the unbound edges of articles in another stack. Where stacks of articles are stacked together, when the bound edge of one stack is aligned with the unbound edge of a lower or upper stack of articles, the result is often referred to as a “compensated” stack or bundle.

Articles, such as flats or mail articles, are placed in trays compatible with machinery, such as sorting apparatuses and the like. In order to facilitate sorting or further processing of the articles in the trays, the articles are loaded into the trays with the bound edges of the articles in the same orientation. Articles from more than one stack may be loaded into a single tray or piece of equipment. Because the bound edges of the various stacks are alternating, the automatic unloading apparatus needs to know the orientation of the bound edges of the articles within the stack. A smart stack may be created by bundling articles together with a stack guide thereon.

FIG. 1 depicts a perspective view of a smart stack 110 having a stack guide 100. The stack guide 100 is placed on top of a stack 110 of articles during the bundling process. The bundling process comprises placing articles into a stack. The bound edge of all the articles may be aligned such that the resulting stack 110 has a bound edge 120 and an unbound edge 130. Straps 140 are placed around the stack 110 such that the stack guide 100 is disposed between the topmost article 115 of the stack 110 and the straps 140, and is held in place by the force of the straps 140 binding the stack 110 together. In some embodiments, the stack guide 100 may be disposed between the straps 140 and a stack protector (not shown), which is located on the topmost article 115.

When a plurality of stacks 110 are stacked on each other, as is done when storing or staging the stacks 110 for transport or other processes, the bound edge 120 of one the stacks 110 is positioned above the unbound edge 130 of an adjacent stack 110, to create compensated stacks.

In some embodiments, the articles within a stack may have an address or destination identifier attached to or imprinted thereon. In some embodiments, the addresses or destination identifiers may be uniformly aligned within the stack 110 so that the stack guide 100 is placed on the surface of the articles having the address or delivery destination identifier.

The stack 110 including the stack guide 100 may be configured for processing using an automatic unloading apparatus (not shown). The automatic unloading apparatus may be any apparatus configured to interact with the stack guide on a stack of articles as described herein. The automatic unloading apparatus may be controlled by a processor connected to a memory and a database. A person of skill in the art will understand that the stack guide can be used in a variety of automatic unloading apparatuses without departing from the scope of the present disclosure. Some embodiments of the automatic unloading apparatus will be described below.

FIG. 2 depicts a top plan view of a stack guide on a stack. The stack guide 100 is disposed on or in proximity to topmost article 215 in a stack 210 and underneath straps 240. The stack 210 has a bound edge 220 and an unbound edge 230. The stack guide comprises strap channels 245, a stack identifier 250, a stack orientation indicator 260, and a supplemental identifier 270. The stack guide 100 may be composed of a variety of materials, such as, for example, plastic, metal, wood, cardboard, durable paper, or other material which can withstand tearing or ripping. The stack guide 100 may comprise a material that can withstand a force applied to the stack guide 100 by the straps 240, which hold the stack guide in place. The stack guide 100 may be molded, cast, or otherwise formed as a single piece. In some embodiments, the stack guide 100 may comprise one or more piece fastened together by welding, brazing, gluing, fastening, melting, or any other desired method.

The strap channels 245 may comprise a depression within the stack guide 100, such that some surfaces of the stack guide 100 are in a different plane from the strap channels 245. The strap channels 245 are sized to accommodate the width of the straps 240 used to bind the articles in the stack 210 together. The strap channels 245 have a bottom surface 246 which is in contact with the straps 240 when the stack 210 is bundled, and have side surfaces 247 which extend in a plane generally perpendicular to the bottom surface 246, which extend generally upward to other surfaces of the stack guide 100, and which align the straps 240 within the stack guide 100.

The presence and orientation of the strap channels 245 guides the location of the straps 240 on the stack guide 100 and provides an easily identifiable location for the straps 240. During unbundling in the automatic unloading apparatus (not shown), the straps in one embodiment need to be cut. The automatic unloading apparatus cuts the straps during the unloading process. By using strap channels 245, the automatic unloading apparatus can easily identify the location of the straps, and position its cutting mechanism to cut the straps. The stack guide has a thickness (not shown) between the bottom surface 247 of the strap channels 245 and the bottom of the stack guide 100, which elevates the straps 240 off the surface of the topmost article 215, and creates a gap 248 between the straps 240 and the topmost article 215 of the stack 210. This gap allows for easier cutting of straps by the automatic unloading apparatus without damage to the articles in the stack 210.

The stack identifier 250 stores information which can be read by an unbundling apparatus. As depicted in FIG. 2, the stack identifier 250 is depicted as a barcode, but the stack identifier 250 is not limited to barcodes. The stack identifier may be a one or two-dimensional barcode, a QR code, an RFID tag, a high capacity color code, a fluorescent marking, or any other type of marking or information encoding symbol or image.

The stack identifier 250 may store or encode information which may have relevance to information about the stack 210. For example, in some embodiments, the stored information may relate to a classification of the articles, the dimensions of the articles in the stack 210, the number of articles in the stack 210, types of articles, the delivery destination, such as a ZIP code, specifically if the articles are mail pieces or flats, or any other desired information.

The stack information may be stored in a database, where the information is associated with the stack identifier 250, and is accessible upon reading the stack identifier 250. For example, where the stack identifier 250 is a barcode, the automatic unloading apparatus may comprise a barcode reader in communication with a database. When the barcode reader reads the stack identifier 250, information about the stack can be communicated to the automated stack unloading apparatus and can be used to direct further processing of the stack 210. In some embodiments, the stack identifier may comprise a computer readable code, such as a barcode, and an alphanumeric identifier, such as a numerical code or a zip code.

In some embodiments, the automatic unloading apparatus may read the stack identifiers 250 of a plurality of stacks 210, and may unload stacks having similar delivery destinations or sizes into the same trays or into the same sorting apparatus. In some embodiments, the automatic unloading apparatus may receive the number of articles in a stack 210 from the stack identifier 250 and use this information to apportion a plurality of stacks 210 into a plurality of trays for later processing.

The stack orientation indicator 260 may be disposed on a surface of the stack guide opposite the stack identifier 250, on the other side of the strap channel 245, with the strap channel 245 disposed between the stack identifier 250 and the stack orientation indicator 260. The stack orientation indicator 260 may comprise a marking, such as an arrow, an alphanumeric string, or another image that indicates which edge of the stack 210 is the bound edge 220. In some embodiments, the stack orientation indicator 260 may indicate which edge of the stack 210 is the unbound edge 230. In some embodiments, the marking may be readable by a visual identification system, an optical recognition system, or other marking identification system located on the automatic unloading apparatus. For example, the stack orientation indicator 260 may be an arrow which points to the bound edge 220. The automatic unloading apparatus may have an optical input system which can detect and read the arrow, and thus determine the orientation of the stack 210 with regard to the bound edge 220. Using this information, the automatic unloading apparatus can rotate the stack 210 as necessary to ensure the articles in the stack 210 are unloaded into a tray or sorting apparatus with bindings of all the articles uniformly aligned.

In some embodiments, the stack orientation indicator 260 may comprise a depression, a concavity, a convexity, a raised pattern, a recessed pattern, or other dimensional feature. In some embodiments, when the stack 215 is initially bundled, the smart stack 200 is placed on the stack 210 such that the side of the stack guide 100 having the stack orientation indicator is always oriented proximal to the bound edge 220. In some embodiments, the stack orientation indicator is always oriented proximal to the unbound edge 230. In some embodiments, the stack orientation indicator is sized, or configured to interact with an orientation feature on the automatic unloading apparatus. For example, the stack orientation indicator 260 may be a depression or concavity sized to receive a probe, sensor, or a mechanical engagement device. Upon interaction of the orientation feature with the depression or concavity of the stack orientation indicator 260, the probe, sensor, or other device may be actuated or may otherwise signal that the probe has engaged the stack orientation indicator 260. When the orientation feature engages the stack orientation indicator 260, the orientation of the stack 210 becomes known and the orientation information may be stored in the automatic unloading apparatus.

The supplemental identifier 270 may act as a backup identifier to the stack identifier 250. The same information or data may be encoded in both the supplemental identifier 270 and the stack identifier 250. For example, if the stack identifier 250 becomes damaged, unreadable, obliterated, destroyed, or otherwise altered such that the stack identifier 250 cannot be read, the supplemental identifier 270 may provide the information accessible via the stack identifier 250.

In some embodiments, the supplemental identifier 270 may provide a confirmation of the information or identity of the stack. For example, in some embodiments, the automatic unloading machine may read the stack identifier 250 and then read the supplemental identifier 270. If the information provided or encoded by both match, the stack 210 and the stack guide 100 may be verified. If the information does not match, this may signal an error or initiate other action.

The supplemental identifier 270 may be a one or two-dimensional barcode. The supplemental identifier 270 may be an additional identifier, image, or marking that contains or encodes information as a back-up to the stack identifier 250, or in addition to the stack identifier 250. In some embodiments, the stack identifier 250 and the supplemental identifier may be of two different types. For example, the stack identifier 250 may be a barcode, and the supplemental identifier 270 may be an RFID tag. By having two types of identifiers, the stack guide 100 may be capable of use in automatic unloading apparatuses whether they have a barcode reader, and RFID reader, or both.

The supplemental identifier 270 may be an image, mark, alphanumeric string, or barcode that communicates any other desired information regarding the processing of the stack 210. For example, the supplemental identifier may comprise information regarding the entity that bundled the stack 210, the shipper of the articles in the stack 250, the manufacturer of the stack guide 100, or any other desired information. In some embodiments, the stack guide 100 does not include a supplemental identifier 270.

Although depicted as a square, the stack guide 100 may be of any shape convenient and acceptable to be bundled with a stack 210. For example, the stack guide may be circular, ovoid, rectangular, triangular, polygonal, or any other desired shape.

FIG. 3 is a block diagram depicting an embodiment of an automatic unloading apparatus. An automatic unloading apparatus 300 comprises a processor 310, a database 320, a scanner 330, an orientation identifier 340, a rotation mechanism 350, a strap identifier 360, a strap cutting mechanism 370, and a pallet scanner 380.

The automatic unloading apparatus 300 is configured to receive a stack 210 of articles having a stack guide 100 bundled thereto using straps 240. The processor 310 controls the operations of the various components of the automatic unloading apparatus, and is in electrical communication with the same. The processor 310 may have onboard memory (not shown) or may be connected to external memory (not shown) which may contain the programming and instructions for controlling the processor 310. The processor 310 is in electrical communication with the database 320. The database 320 is linked to or associated with the stack identifier 250, and contains information about the stack 210 to which the stack guide 100 is applied. For example, in some embodiments, the information stored in the database may relate to a classification of the articles, the dimensions of the articles in the stack 210, the number of articles in the stack 210, types of articles, the delivery destination, such as a ZIP code, specifically if the articles are mail pieces or flats, or any other desired information.

The scanner 330 is configured to read or scan the stack identifier 250, and may be any scanner capable of reading the stack identifier 250, e.g., barcode scanner, QR reader, RFID reader, visual recognition system, and the like. Upon reading the stack identifier 250, the scanner 330 communicates the read information or code to the processor 310, which then queries database 320 using the code or value encoded in the stack identifier 250 to access the stored information. The processor receives the information about the stack 210 corresponding to the stack identifier 250, and uses that information for further processing of the stack, for example, the information may provide instructions as to how to separate the articles into trays or sorting equipment.

The orientation identifier 340 is configured to detect the orientation of the stack 210 by reading the stack orientation identifier 360. In some embodiments, the orientation identifier may be a visual recognition system capable of reading an image and interpreting the image, or it may be a mechanical probe, or other device capable of reading, recognizing, or interpreting the stack orientation indicator 260. The orientation identifier 340 receives information regarding the orientation of the stack 210 using the stack orientation indicator 260, and determines whether the stack is properly oriented. In some embodiments, the orientation identifier 340 may communicate information to the processor 310, and then the processor 310 may determine whether the bound edge 220 of the stack 210 is appropriately oriented for processing or unloading into trays. The processor 310 is in electrical communication with the rotation mechanism 350, and if the orientation identifier 340 determines that the stack 210 is improperly oriented, the rotation mechanism receives a signal from the processor 310 to rotate the stack 210 an appropriate amount so that the stack 210 is properly aligned for processing.

The strap identifier 360 may comprise a visual recognition system capable of identifying the location of the straps based on the position of the stack guide 300. The strap identifier 360 may explicitly determine the location of the straps 240 by identifying the depression in the stack guide 100 made by the strap channels 245 and then identifying a contrasting color or texture of the straps 240. In some embodiments, the strap identifier 360 may implicitly determine the location of the straps 240 by identifying the stack guide 100 and interpolating the position of the straps 240 based on knowing the dimensions and layout of the stack guide 100. The strap identifier determines the location of the straps 360 in order to direct the strap cutting mechanism 370 to the appropriate location to cut the straps 240 without damaging the topmost article 215, or any other article, in the stack 210. In some embodiments, the strap cutting mechanism 370 is advantageously directed to the gap 248 between the straps 240 and the topmost article 215 due to the thickness of the stack guide 100.

The pallet scanner 380 comprises a visual recognition system configured to identify the location of the stack guides 100 of the plurality of stacks 210 on pallet 412. This visual recognition system identifies the location of the stack guide 100, and communicates the location to the processor, which, in turn, may direct the scanner 330, orientation identifier 340, and/or the strap identifier 360 to be moved into proximity with the stack guide 100.

FIG. 4 depicts a perspective view of an embodiment of an automatic unloading apparatus 300. The automatic unloading apparatus comprises a robot 450 and a conveyor 460. The robot 450 comprises a robotic arm 451, a base 452, and an effector 455. The robotic arm 451 may be articulated or otherwise configured to manipulate a stack 210 of articles bound with a stack guide 100. The robotic arm 451 is jointed and configured to have a range of motion in an x, y, and z direction. In some embodiments, the robotic arm 451 is configured to move a stack 210 onto the conveyor 460. The conveyor 460 may be configured to hold trays, or may be part of a sorting apparatus, or any other processing apparatus. The robot 450 may be controlled by the processor 310. In some embodiments, the processor 310 is onboard the robot 450. In some embodiments, the robot 450 is configured to receive signals generated in the processor, such as signals from hydraulic or electric motors.

The base 452 is coupled to a surface, such as a floor or the ground, to provide support for the robot 450. The base 452 may be rotatably coupled to the ground and the robotic arm 451. The base 452 may comprise a rotation or swivel mechanism such that that the robotic arm 451 can rotate in a 360° arc about the center of the base 452.

The robotic arm 451 may comprise the rotation mechanism 350, which may be a joint within the robotic arm, which allows the robotic arm 451 to manipulate the stack 210 through 360° of motion in order to rotate the stack 210 as required to align the bound edge as described herein.

The robot 450 described herein is exemplary only. A person of skill in the art would understand that the robot 450 may be of a similar or different design without departing from the scope of the present development.

The effector 455 is connected to an end of the robotic arm 451. The effector 455 may comprise the scanner 330, the orientation identifier 340, the strap identifier 360, and the strap cutting mechanism 370. In some embodiments, the effector 455 may comprise a visual recognition system, which comprises the scanner 330, the orientation identifier 340, and the strap identifier 360. The processor is in communication with the effector 455 or components thereof, and/or the visual recognition system. This communication may be hardwired, or may be wireless communication over a wireless network using a known wireless communication protocol.

The automatic unloading apparatus 300 may further comprise a first bin 470 and a second bin 480. The first bin 470 may be positioned in proximity to the robotic arm 451 such that the robot 450 can deposit a stack guide removed from the stack 210, for later reuse or recycling of the stack guide 100. The second bin 480 may be positioned in proximity to the robotic arm 451 such that the robot 450 can deposit straps removed from the stack 210.

A pallet 412 containing a plurality of stacks 410 thereon may be positioned near the robotic arm 451, such that the robotic arm 451 can position the effector 455 in contact with one of the plurality of stacks 410, read the stack identifier 250, the orientation indicator 260, and/or the supplemental identifier 270, and engage the stack 210 for repositioning of the stack 210 onto the conveyor 460 or other similar apparatus.

FIG. 5 illustrates a method of handling a stack 210 using a smart stack or stack guide 100. The process 500 begins in block 502 wherein a stack 210 bundled with a stack guide 100 is received. A plurality of stacks 210 positioned on the pallet 412 may be received in the automatic unloading apparatus 300.

Once the stack 210 is received, the process 500 moves to block 504, wherein the stack identifier 250 is read using the scanner 330. The robotic arm 451 may position the effector 455 in close proximity to the stack guide 200, at which point the scanner 330 can read the stack identifier 250. For ease of discussion, use of a barcode is discussed here, but this does not limit the scope of the present development, as a person of skill in the art would understand that other identifiers could be used for the stack identifier 250. As described above, this may be accomplished by using the scanner 330, which may read an RFID tag, a barcode, a QR code reader, or may be a computerized visual recognition system. Upon reading the barcode of stack identifier 250 using the scanner 330, the automatic unloading apparatus 300 queries the database 320 using the scanned barcode. A record associated with the scanned barcode is retrieved from the database 320, and the information from the record is used for processing the stack 210. This information may be used to categorize the stack 210 according to the delivery destination, the dimensions of the stack 210, the number of articles in the stack 210, and/or any other desired information. In some embodiments, the automatic unloading apparatus 300 can unload and unbundle stacks 210 to prepare the articles for sorting or loading into trays or onto the conveyor 460. Articles having similar destinations may be unloaded into trays or sorted in a specified order. The information from the scanned barcode may direct the automatic unloading apparatus 300 on how to place the articles from the stack 210 into the trays, or when to unbundle the stack 210.

In some embodiments, the automatic unloading apparatus 300 may receive information from the scanned barcode relating to the dimensions of the articles in the stack 210, and may use this information to unload the articles of the stack 210 into an appropriately sized tray or portion of a sorting apparatus. In some embodiments, as described above, the automatic unloading apparatus 300 may use the information obtained by scanning the barcode to apportion articles among a plurality of trays, according to the number of articles in the stack 210.

The process 500 next moves to decision state 506, wherein the orientation of the stack 210 is determined. As described above, a plurality of stacks 210 may be received in larger stacks which have a plurality of stacks 210 stacked on each other, with the orientation of the stacks 210 within the larger stacks alternating according to the bound edge 220 and the unbound edge 230. As a result, when the stack 210 is received into the automatic unloading apparatus 300, the orientation of the stack 210 may not be suitable for unloading into trays or a sorting apparatus, because in trays or sorting apparatuses, the bound edges are desirably uniformly positioned within the tray or sorting apparatus. Therefore, the automatic unloading apparatus 300 detects the orientation of the stack using the orientation identifier 340 to read the stack orientation indicator 260. As described above, the stack orientation indicator may be an arrow which is recognizable by a computerized visual recognition system. In some embodiments, the orientation identifier may comprise a computerized visual recognition system. In some embodiments, the stack orientation indicator 260 may be an arrow which points to the bound edge 220, or in some embodiments, to the unbound edge 230, which can be recognized and interpreted by the computerized visual recognition system. Upon determining where the bound edge 220 or the unbound edge 230 is located, the automatic unloading apparatus 300 can determine how the stack 210 is oriented.

In some embodiments, the stack orientation indicator 260 may be a physical concavity into which the orientation identifier 340, in the form of an orientation probe or the like, may be inserted. Specifically, an orientation probe may be lowered into contact with the stack guide 100. If the stack 210 is oriented properly, the orientation probe can releasably engage with the stack orientation indicator 260, and thereby confirm the orientation of the stack 210. If the stack 210 is not oriented properly, the orientation probe will contact a surface of the stack guide 100 which lacks the stack orientation indicator 260, no engagement will occur, and thereby orientation identifier 340 will determine that the stack 210 is improperly oriented.

If the stack 210 is not properly oriented, it may be rotated into the proper alignment. In some embodiments, the automatic unloading apparatus receives the stack 210 in the rotation mechanism 350, which may comprise a rotatable platform or a mechanical arm configured to rotate the stack 210. In some embodiments, the automatic unloading apparatus rotates the stack 180°. In some embodiments, the rotation mechanism 350 may rotate the stack 210 45°, 90°, 135°, 270°, 315°, or any amount therebetween. Upon rotation of the stack 210, the process 500 returns to block 506, wherein the orientation of the stack is determined.

If the stack is properly oriented, the process 500 moves to block 412, wherein the strap identifier 360 identifies the location of the straps 240. As described above, the strap identifier 360 may be a computerized visual recognition system which identifies the location of the strap channels 245. In some embodiments, the strap channels 245 or the stack guide 100 may comprise a color or texture which contrasts with the color or texture of the topmost article 215 of the stack 210, in order to provide an easily identifiable stack guide 100 or strap channel 245. In some embodiments, the stack guides 200 are all of identical dimensions. The visual recognition system may identify the location of the stack guide, and, using the uniformity of dimensions among stack guides 200, the visual recognition system will know where the straps 240 are located by knowing the location of the stack guide 100.

Upon determining the location of the straps 240, the process 400 moves to block 514, wherein the robotic arm 451 places the stack 210 on the conveyor 460.

Once the stack 210 is on the conveyor 460, the process 500 moves to step 516, wherein the straps 240 are cut by inserting the strap cutting mechanism 370 into the gap 248 and activating the strap cutting mechanism 370, thereby cutting the straps without damaging the articles, including the topmost article 215 of the stack 210. The process next moves to block 416 wherein the articles from the stack 210 are unloaded into a tray or sorting apparatus such that the bound edges 220 of the articles are all uniformly aligned.

The process 500 moves to block 518, wherein the stack guide and the straps are disposed of. The effector 455 picks the stack guide 210 and the straps 240, and deposits them in the first and second bins respectively. The process ends in block 520.

In some embodiments, the stack guide 100 may comprise an embedded processor connected to a memory and having a communication port. Stack information may be written to the embedded processor and memory during bundling. The stack information stored on the embedded processor and the memory, may then be accessible to the automated unloading apparatus. Thus, a single stack guide 100 may be used and reused for various stacks having different stack information by writing and/or rewriting stack information to the embedded processor and memory.

The steps of the method described above are exemplary only. A person of skill in the art would understand that the order of steps of the process could be performed in a different order, and one or more steps may be excluded, as desired.

The foregoing description details certain embodiments of the systems, devices, and methods disclosed herein. It will be appreciated, however, that no matter how detailed the foregoing appears in text, the systems, devices, and methods can be practiced in many ways. As is also stated above, it should be noted that the use of particular terminology when describing certain features or aspects of the development should not be taken to imply that the terminology is being re-defined herein to be restricted to including any specific characteristics of the features or aspects of the technology with which that terminology is associated.

The technology is operational with numerous other general purpose or special purpose computing system environments or configurations. Examples of well-known computing systems, environments, and/or configurations that may be suitable for use with the development include, but are not limited to, personal computers, server computers, hand-held or laptop devices, multiprocessor systems, microprocessor-based systems, programmable consumer electronics, network PCs, minicomputers, mainframe computers, distributed computing environments that include any of the above systems or devices, and the like.

As used herein, instructions refer to computer-implemented steps for processing information in the system. Instructions can be implemented in software, firmware or hardware and include any type of programmed step undertaken by components of the system.

A microprocessor may be any conventional general purpose single- or multi-chip microprocessor such as a Pentium® processor, a Pentium® Pro processor, a 8051 processor, a MIPS® processor, a Power PC® processor, or an Alpha® processor. In addition, the microprocessor may be any conventional special purpose microprocessor such as a digital signal processor or a graphics processor. The microprocessor typically has conventional address lines, conventional data lines, and one or more conventional control lines.

The system may be used in connection with various operating systems such as Linux®, UNIX® or Microsoft Windows®.

The system control may be written in any conventional programming language such as C, C++, BASIC, Pascal, or Java, and ran under a conventional operating system. C, C++, BASIC, Pascal, Java, and FORTRAN are industry standard programming languages for which many commercial compilers can be used to create executable code. The system control may also be written using interpreted languages such as Perl, Python or Ruby.

Those of skill will further recognize that the various illustrative logical blocks, modules, circuits, and algorithm steps described in connection with the embodiments disclosed herein may be implemented as electronic hardware, software stored on a computer readable medium and executable by a processor, or combinations of both. To clearly illustrate this interchangeability of hardware and software, various illustrative components, blocks, modules, circuits, and steps have been described above generally in terms of their functionality. Whether such functionality is implemented as hardware or software depends upon the particular application and design constraints imposed on the overall system. Skilled artisans may implement the described functionality in varying ways for each particular application, but such embodiment decisions should not be interpreted as causing a departure from the scope of the present development.

The various illustrative logical blocks, modules, and circuits described in connection with the embodiments disclosed herein may be implemented or performed with a general purpose processor, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field programmable gate array (FPGA) or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof designed to perform the functions described herein. A general purpose processor may be a microprocessor, but in the alternative, the processor may be any conventional processor, controller, microcontroller, or state machine A processor may also be implemented as a combination of computing devices, e.g., a combination of a DSP and a microprocessor, a plurality of microprocessors, one or more microprocessors in conjunction with a DSP core, or any other such configuration.

If implemented in software, the functions may be stored on or transmitted over as one or more instructions or code on a computer-readable medium. The steps of a method or algorithm disclosed herein may be implemented in a processor-executable software module which may reside on a computer-readable medium. Computer-readable media includes both computer storage media and communication media including any medium that can be enabled to transfer a computer program from one place to another. A storage media may be any available media that may be accessed by a computer. By way of example, and not limitation, such computer-readable media may include RAM, ROM, EEPROM, CD-ROM or other optical disk storage, magnetic disk storage or other magnetic storage devices, or any other medium that may be used to store desired program code in the form of instructions or data structures and that may be accessed by a computer. Also, any connection can be properly termed a computer-readable medium. Disk and disc, as used herein, includes compact disc (CD), laser disc, optical disc, digital versatile disc (DVD), floppy disk, and Blu-ray disc where disks usually reproduce data magnetically, while discs reproduce data optically with lasers. Combinations of the above should also be included within the scope of computer-readable media. Additionally, the operations of a method or algorithm may reside as one or any combination or set of codes and instructions on a machine readable medium and computer-readable medium, which may be incorporated into a computer program product.

The foregoing description details certain embodiments of the systems, devices, and methods disclosed herein. It will be appreciated, however, that no matter how detailed the foregoing appears in text, the systems, devices, and methods can be practiced in many ways. As is also stated above, it should be noted that the use of particular terminology when describing certain features or aspects of the development should not be taken to imply that the terminology is being re-defined herein to be restricted to including any specific characteristics of the features or aspects of the technology with which that terminology is associated.

It will be appreciated by those skilled in the art that various modifications and changes may be made without departing from the scope of the described technology. Such modifications and changes are intended to fall within the scope of the embodiments. It will also be appreciated by those of skill in the art that parts included in one embodiment are interchangeable with other embodiments; one or more parts from a depicted embodiment can be included with other depicted embodiments in any combination. For example, any of the various components described herein and/or depicted in the Figures may be combined, interchanged or excluded from other embodiments.

With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity.

It will be understood by those within the art that, in general, terms used herein are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to embodiments containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and/or “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to “at least one of A, B, and C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogous to “at least one of A, B, or C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase “A or B” will be understood to include the possibilities of “A” or “B” or “A and B.”

All references cited herein are incorporated herein by reference in their entirety. To the extent publications and patents or patent applications incorporated by reference contradict the disclosure contained in the specification, the specification is intended to supersede and/or take precedence over any such contradictory material.

The term “comprising” as used herein is synonymous with “including,” “containing,” or “characterized by,” and is inclusive or open-ended and does not exclude additional, unrecited elements or method steps.

All numbers expressing quantities of ingredients, reaction conditions, and so forth used in the specification and claims are to be understood as being modified in all instances by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the specification and attached claims are approximations that may vary depending upon the desired properties sought to be obtained by the present development. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should be construed in light of the number of significant digits and ordinary rounding approaches. The above description discloses several methods and materials of the present development. This development is susceptible to modifications in the methods and materials, as well as alterations in the fabrication methods and equipment. Such modifications will become apparent to those skilled in the art from a consideration of this disclosure or practice of the development disclosed herein. Consequently, it is not intended that this development be limited to the specific embodiments disclosed herein, but that it cover all modifications and alternatives coming within the true scope and spirit of the development as embodied in the attached claims. 

What is claimed is:
 1. A stack guide comprising: a first surface configured to be supported in a fixed location with respect to an article in a stack of articles; a second surface which comprises: a securing guide configured to receive one or more securing members for bundling the stack of articles; and at least one information source, the information source including a stack identifier and a stack orientation indicator.
 2. The stack guide of claim 1 further comprising a supplemental identifier.
 3. The stack guide of claim 1, wherein the stack identifier is a one or two-dimensional barcode.
 4. The stack guide of claim 1, wherein the stack orientation indicator is a marking recognizable by a computerized visual recognition system.
 5. The stack guide of claim 1, wherein the supplemental identifier comprises an RFID tag.
 6. The stack guide of claim 1, wherein the articles are articles of mail.
 7. The stack guide of claim 1, wherein the securing guide forms a depression in the second surface, and wherein the stack identifier and the stack orientation indicator are disposed on opposite sides of the strap channel.
 8. A system for bundling articles into a stack comprising: a plurality of articles arranged into a stack, having the bound edge of each of the plurality of articles aligned within the stack; a first surface configured to be supported in a fixed location with respect to an article in a stack of articles; a second surface which comprises: a securing guide configured to receive one or more securing members for bundling the stack of articles; and at least one information source, the information source including a stack identifier and a stack orientation indicator a securing guide configured to receive one or more straps for bundling the stack of articles; and wherein the stack identifier and the stack orientation indicator are disposed on opposite sides of the securing guide; and one or more straps surrounding the stack of articles and passing through the securing guide, wherein a gap is created between the strap and a topmost article in the stack proximate to the stack guide.
 9. The system of claim 8, further comprising an automatic unloading machine, wherein the automatic unloading machine is configured to read the stack identifier and the stack orientation indicator.
 10. The system of claim 9, wherein the automatic unloading machine further comprises a cutting tool.
 11. The system of claim 10, wherein the gap between the strap and the topmost article in the stack is sized to accept the cutting tool on the automatic unloading machine.
 12. The system of claim 8 wherein the stack guide further comprises a supplemental identifier.
 13. The system of claim 8, wherein the stack identifier is a one or two-dimensional barcode.
 14. The system of claim 8, wherein the stack orientation indicator is a marking recognizable by a computerized visual recognition system.
 15. The system of claim 8, wherein the supplemental identifier comprises an RFID tag.
 16. The system of claim 8, wherein the stack of articles comprises articles of mail.
 17. The system of claim 8, wherein the securing guide forms a depression in the second surface.
 18. A method of processing a stack of articles comprising: receiving, into an automatic unloading apparatus, a stack of articles which are bound with a binding material and which includes a stack guide; reading a stack identifier disposed on the stack guide; retrieving stack information corresponding to the stack identifier from a database; identifying the orientation of the stack using an orientation identifier disposed on the stack guide; rotating the stack in response to the identified orientation; identifying the location of the straps; cutting the straps; and unloading the articles from the stack in response to the retrieved stack information.
 19. The method of claim 18 further comprising placing the articles from the stack into a tray with a bound edge of each of the articles aligned.
 20. The method of claim 18, wherein the stack guide further comprises a supplemental identifier.
 21. The method of claim 18 further comprising reading the supplemental identifier.
 22. The method of claim 18, wherein the stack of articles comprises articles of mail.
 23. A system of processing a stack of articles comprising: means for receiving, into an automatic unloading apparatus, a stack of articles which are bound with a binding material and which includes a stack guide; means for reading a stack identifier disposed on the stack guide; means for retrieving stack information corresponding to the stack identifier from a database; means for identifying the orientation of the stack using an orientation identifier disposed on the stack guide; means for rotating the stack in response to the identified orientation; means for identifying the location of the straps; means for cutting the straps; and means for unloading the articles from the stack in response to the retrieved stack information. 